Manufacturing method of a drawn cup needle roller bearing having seal ring

ABSTRACT

A drawn cup needle roller bearing  30  having a seal ring comprises: a shell  31  having a raceway surface  31   a  on an inner circumferential face and also having inward flange portions  31   b,    31   c  in both end portions; a cage  32  having a plurality of pockets  32   a  in a circumferential direction and worked by cutting; a plurality of needles  33  retained in the pockets  32   a  so that the needles freely rotate along the raceway surface  31   a ; and a seal ring  34 , the shape of which is cylindrical, arranged inside the shell  31  between an end face  32   b  of the cage  32  and the inward flange portion  31   b . The seal ring  34  composes a floating seal and is formed by press working. Due to the foregoing, an excellent dimensional accuracy can be provided and a quantity of lubricant passing through the bearing can be controlled.

TECHNICAL FIELD

The present invention relates to a drawn cup needle roller bearinghaving a seal ring and a manufacturing method thereof.

BACKGROUND ART

Conventionally, a large number of plain bearings (bushes) have been usedfor automatic transmissions. However, in order to prevent seizure causedin the bushes or to reduce torque required for the automatictransmissions, the plain bearings have been substituted by drawn cupneedle roller bearings.

As the drawn cup needle roller bearing, it is known to use a drawn cupneedle roller bearing, the thickness of which is reduced so that theheight of the cross section of the bearing can be 1.5 to 2.5 mm, or adrawn cup needle roller bearing having a seal ring so that a quantity oflubricant passing through the needle bearing can be the same as that ofthe bush (For example, refer to Patent Documents 1 to 3).

Specifically, a drawn cup needle roller bearing 100 shown in FIG. 21includes: a shell (an outer ring having a flange) 101; a cage 102; and aplurality of needles 103, wherein the height of the cross section of thebearing is approximately 1.5 mm and shaft diameter is 17 to 33 mm. Adrawn cup needle roller bearing 110 shown in FIG. 22 includes: a shell111; a cage 112; and a plurality of needles 113. The drawn cup needleroller bearing 110 further includes a seal ring 114, the height of thecross section of which is approximately 2 mm for controlling a quantityof lubricant passing through the needle bearing, wherein the height ofthe cross section of the bearing is 3 to 3.5 mm and the shaft diameteris 13 to 43 mm.

The seal ring 114 of the drawn cup needle roller bearing 110 shown inFIG. 22 is made by cutting working. After completing the cuttingworking, heat treatment is executed for preventing abrasion caused by acontact with an opponent member.

-   Patent Document 1; Japanese Patent Unexamined Publication    JP-A-6-294418-   Patent Document 2: Japanese Patent Unexamined Publication    JP-A-2000-291669-   Patent Document 3: Japanese Utility Model Unexamined Publication    JP-UM-B-6-23776

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention

In a meantime, the following problems may be encountered in the abovedrawn cup needle roller bearings. In the drawn cup needle roller bearing100 shown in FIG. 21, it is necessary to control a quantity of lubricantpassing through the needle bearing. On the other hand, in the drawn cupneedle roller bearing 110 shown in FIG. 22, since the seal ring 114 ismade by cutting working, it is impossible to ensure the requiredaccuracy such as circularity of the inner diameter of the seal ring ordimensional tolerance of the inner diameter.

The present invention has been accomplished in view of the abovecircumstances. An object of the present invention is to provide a drawncup needle roller bearing having a seal ring, the dimensional accuracyof which is high, capable of controlling a quantity of lubricant passingthrough the needle bearing.

Means for Solving the Problems

(1) A drawn cup needle roller bearing having a seal ring including:

a shell having a raceway surface on an inner circumferential face or anouter circumferential face and also having flange portions in both endportions;

a cage having a plurality of pockets in a circumferential direction;

a plurality of needles retained in the pockets so that the needlesfreely rotate along the raceway surface; and

a cylindrical seal ring arranged inside or outside the shell between anend face of the cage and the flange portion of the cage, wherein

the seal ring composes a floating seal and is formed by press working.

(2) The drawn cup needle roller bearing having a seal ring according to(1), wherein after completing the press working on the seal ring, noheat treatment is executed for the seal ring.

(3) The drawn cup needle roller bearing having a seal ring according to(1), wherein after completing the press working on the seal ring, theseal ring is subjected to the treatment for improving abrasionresistance.

(4) The drawn cup needle roller bearing having a seal ring according to(1), wherein the cage is made of resin.

(5) A method of manufacturing a drawn cup needle roller bearing having aseal ring, the drawn cup needle roller bearing including:

a shell having a raceway surface on an inner circumferential face or anouter circumferential face and also having flange portions in both endportions;

a cage having a plurality of pockets in a circumferential direction;

a plurality of needles retained in the pockets so that the needlesfreely rotate along the raceway surface; and

a cylindrical seal ring composing a floating seal, arranged inside oroutside the shell between an end face of the cage and the flange portionof the shell,

the method of manufacturing a drawn cup needle roller bearing having aseal ring, including the step of forming the seal ring by press working.

Advantages of the Invention

In the drawn cup needle roller bearing having a seal ring and themanufacturing method of the present invention, when the seal ring isformed by press working, it is possible to ensure high dimensionalaccuracy of the seal ring. Therefore, it is possible to prevent abrasionof the seal ring caused when it comes into contact with an opponentmember. Further, since the needle bearing includes the seal ring, it ispossible to control a quantity of lubricant passing through the needlebearing. In addition, since the seal ring is a floating seal, the torquerequired for the bearing can be reduced as compared with a bearing inwhich a contact type seal is used.

After completing the press working on the seal ring, the seal ring isnot subjected to heat treatment. Accordingly, the manufacturing cost canbe reduced.

Further, after completing the press working on the seal ring, the sealring is subjected to the treatment for improving abrasion resistance.Therefore, it is possible to prevent the abrasion of the seal ringcaused by a sliding contact with the flange portion provided at an endportion of the shell. Further, when nitriding is executed at a lowtemperature as the treatment for improving abrasion resistance, theabrasion resistance property of the seal ring can be enhanced while adeformation of the seal ring caused by the treatment for improvingabrasion resistance is being prevented. Therefore, a thin seal ring canbe manufactured with high accuracy.

Although the formation of pockets is difficult for a cage made of metal,especially the formation of pawls for retaining needles is difficult inthe case of the cage made of metal, when the cage is made of resin, athin cage can be easily manufactured at a low manufacturing cost.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view showing a drawn cup needle roller bearinghaving a seal ring of an embodiment of the present invention.

FIG. 2 is a sectional view showing a working step of the firstembodiment of a seal ring. FIG. 2(A) shows a metallic material plate,FIG. 2(B) shows a step of punching out an inner diameter portion, FIG.2(C) shows a step of burring, FIG. 2(D) shows a step of compressiveforming, FIG. 2(E) shows a step of cutting off a cylindrical portion,FIG. 2(F) shows a step of ironing the inner diameter portion, FIG. 2(G)shows a step of cutting off excess portions and FIG. 2(H) shows a stepof re-ironing.

FIG. 3 is a sectional view showing a working step of the secondembodiment of a seal ring. FIG. 3(A) shows a coil base material, FIG.3(B) shows a step of punching out an inner diameter portion, FIG. 3(C)shows a step of burring, FIG. 3(D) shows a step of compressive forming,FIG. 3(E) shows a step of cutting a cylindrical portion, FIG. 3(F) showsa step of ironing the inner diameter portion and FIG. 3(G) shows a stepof cutting excess portion.

FIG. 4 is a sectional view showing a press device used for a separatingstep and a successive re-fitting step in the second embodiment.

FIG. 5 is a sectional view showing a separating step and a re-fittingstep successive to the separating step wherein the steps are shown inthe order of progress. FIG. 5(A) is a view showing a state beforeworking, FIG. 5(B) is a view showing a state in the middle of workingand FIG. 5(C) is a view showing a state in which a ring is returned tothe original state of the coil base material.

FIG. 6 is a sectional view showing a press device used for an ironingstep and a re-fitting step successive to the ironing step in the secondembodiment.

FIG. 7 is a sectional view showing an ironing step and a fitting stepsuccessive to the ironing step, wherein the steps are shown in the orderof progress. FIG. 7(A) is a view showing a state before working, FIG.7(B) is a view showing a state in the middle of working and FIG. 7(C) isa view showing a state in which a ring is returned to the original stateof a coil base material.

FIG. 8 is a sectional view showing a working step of the thirdembodiment of a seal ring. FIG. 8(A) shows a coil base material, FIG.8(B) shows a punching out an inner diameter portion, FIG. 8(C) shows astep of burring, FIG. 8(D) shows a step of compressive forming, FIG.8(E) shows a step of cutting out a cylindrical portion, FIG. 8(F) showsa step of cutting the inner diameter portion and FIG. 8(G) shows a stepof cutting off excess portion.

FIG. 9 is a sectional view showing a working step of the fourthembodiment of a seal ring. FIG. 9(A) shows a coil base material, FIG.9(B) shows a step of punching out an inner diameter portion, FIG. 9(C)shows a step of burring, FIG. 9(D) shows a step of compressive forming,FIG. 9(E) shows a step of cutting off a cylindrical portion, FIG. 9(F)shows a step of ironing the inner diameter portion and FIG. 9(G) shows astep of cutting off excess portion.

FIG. 10 is a sectional view showing a working step of the fifthembodiment of a seal ring. FIG. 10(A) shows a metallic material plate,FIG. 10(B) shows a step of punching out an inner diameter portion, FIG.10(C) shows a step of burring, FIG. 10(D) shows a step of cutting offthe Cylindrical portion and FIG. 10(E) shows a step of cold rollingworking.

FIG. 11 is a side view showing a state in which cold rolling working isexecuted.

FIG. 12 is a sectional view taken on line XII-XII in FIG. 11.

FIG. 13 is an enlarged view showing a portion XIII in FIG. 12. FIG.13(A) shows a state before the start of cold rolling working and FIG.13(B) shows a state after the completion of cold rolling working.

FIG. 14 is a sectional view showing a working step of the sixthembodiment of a seal ring. FIG. 14(A) shows a metallic material plate,FIG. 14(B) shows a step of punching out an inner diameter portion, FIG.14(C) shows a step of burring, FIG. 14(D) shows a step of forming acorner R portion, FIG. 14(E) shows a step of cutting off a cylindricalportion and FIG. 14(F) shows a step of cold rolling working.

FIG. 15 is an enlarged view of a portion XV in FIG. 14(D).

FIG. 16 is an enlarged view made in the same manner as that of FIG. 13.FIG. 16(A) shows a state before the start of cold rolling working andFIG. 16(B) shows a state after completing the cold rolling working.

FIG. 17 is a graph showing results of the measurement of dynamic torqueof a drawn cup needle roller bearing and a bush.

FIG. 18 is a graph showing results of the measurement of a quantity oflubricant passing through a drawn cup needle roller bearing and a bush.

FIG. 19 is a graph in which the outer diameter circularity of a cage iscompared to each other with respect to a forming condition and also withrespect to whether or not annealing is executed.

FIG. 20 is a graph showing an amount of warp of a seal ring caused whenthe seal ring is subjected to a treatment for improving abrasionresistance.

FIG. 21 is a sectional view showing a conventional drawn cup needleroller bearing.

FIG. 22 is a sectional view showing another conventional drawn cupneedle roller bearing having a seal ring which has been subjected tocutting working.

DESCRIPTION OF THE REFERENCE NUMERALS AND SIGNS

-   -   30 Drawn cup needle roller bearing having seal ring    -   31 Shell    -   31 a Raceway surface    -   31 b, 31 c Inward flange portion (flange portion)    -   32 Cage    -   32 a Pocket    -   32 b End face of cage    -   33 Needle    -   34 Seal ring

BEST MODE FOR CARRYING OUT THE INVENTION

Referring to the drawings, the drawn cup needle roller bearing having aseal ring of an embodiment of the present invention will be explained indetail as follows.

The drawn cup needle roller bearing 30 having a seal ring is arrangedbetween gear trains in an automatic transmission or between a gear shaftand a housing, or on the side of an oil pump gear. As shown in FIG. 1,this drawn cup needle roller bearing 30 includes: a shell (an outer ringhaving a flange) 31; a cage 32; a plurality of needles 33; and acylindrical seal ring 34, and rotatably supports a shaft (or an innerring member) not shown.

The shell 31 includes: a raceway surface 31 a provided on the innercircumferential face; and inward flange portions 31 b, 31 c provided atboth end portions. The cage 32 includes a plurality of pockets 32 aarranged in the circumferential direction.

Here, the cage 32 is made of metal, the metal is steel such as SPCC,S10C, AISI-1010, SCM415, SK5 or SUJ2 and is machined by means ofwelding, press working or cutting. The cage 32 may be subjected to theheat treatment of carbonitriding or salt bath soft nitriding (Tufftride)in the same manner as that of the conventional method. However, in thecase of a thin cage applied to a needle bearing of a shaft diameter of40 mm or more, there is a possibility that the needle 33 gets into aspace between the raceway surface 31 a and the outer diameter face ofthe cage 32 due to a deformation caused by the heat treatment executedfor the cage 32. Therefore, in order to prevent the deformation causedby the heat treatment, the cage 32 is subjected to Tufftride SQ (singlequench) or NV nitriding.

When the cage 32 is made of resin, it is possible to apply polyamide 46,polyamide 66 or PPS (polyphenylene sulfide) to the cage 32. Polyamide 46can be continuously used at a temperature of 150° C. and also, can beused at a temperature of 170° C. for an instant. Polyamide 66 can beused at a temperature of 120° C. PPS can be used at a temperature of200° C. In order to enhance the mechanical strength, glass fiber ismixed in each resin material by 20 to 30%.

When the height of the cross section of the drawn cup needle rollerbearing 30 is approximately 1.5 to 2.5 mm, the thickness of the cage issmall and 1 mm or less. By forming the thin cage by the resin asdescribed above, pockets and pawls for retaining the needles can beeasily formed as compared with the cage made of metal.

For example, in the cage 32 made of resin, the inner diameter of whichis 45 mm, the accurate circularity is required. In order to manufacturea cage made of resin with high accuracy, it is effective to executeannealing after performing an injection molding of the cage.

The needle 33 is retained in each pocket 32 a of the cage 32 beingcapable of freely rolling so that the needle 33 can freely rotate alongthe raceway surface 31 a of the shell 31. Crowning working is performedon both end portions of the needle 33.

The seal ring 34 is made of steel such as SPCC, SPCE or SUJ2. The sealring 34 is arranged between the end face 32 b of the cage 32 and theinward flange portion 31 b of the shell 31, which is on a downstreamside of a flow of the lubricant inside the shell and regulates aquantity of lubricant passing through the needle bearing 30. The sealring 34 may be made of non-ferrous metal such as copper, copper alloy,aluminum or aluminum alloy, as necessary. Further, it the followingworking method of the embodiment is used, the seal ring 34 is preferablymade of SPCC or SPCE. The seal ring 34 is a floating seal, of whichouter diameter is slightly larger than the outer diameter of the shaftand slightly smaller than the inner diameter of the shell 31.

The drawn cup needle roller bearing 30 is made thin as follows. Theheight of the cross section of the needle bearing is 1.0 to 3.5 m,preferably 1.5 to 2.5 mm and more preferably 1.5 to 2.0 mm and the shaftdiameter is preferably 100 mm or less. The height of the cross sectionof the seal ring 34 arranged in the shell 31 is 0.8 to 1.8 mm. The sealring 34 having the dimensions and shape described above is formed bymeans of press working (in the embodiment, dimension regulating step,punching step, and re-punching step, which are described later) or coldrolling working. Thus, the surface hardness is improved due to workinghardening. Therefore, the seal ring 34 can be manufactured withoutexecuting the heat treatment such as quenching and tempering as a laterprocess. Accordingly, the dimensional accuracy of the seal ring 34 ishigh without being deformed by the heat treatment. As necessary, forexample, according to the condition in which the drawn cup needle rollerbearing 30 is used, the seal ring 34 may be subjected to the treatmentfor improving abrasion resistance such as nitriding.

Specifically, the seal ring 34 is made by the following working method.

First Working Method

In this working method, first, as shown in FIG. 2(A), a metal plate 1made of mild steel or stainless steel, which is a material of the sealring, is subjected to piercing working and a first preliminaryintermediate material 3 having a circular hole 2 is obtained as shown inFIG. 2(B). Next, this first preliminary intermediate material 3 issubjected to burring working in which the periphery of the circular hole2 is bent so as to be right angle with respect to the metal plate 1 allover the circumference. Due to the foregoing, a second preliminaryintermediate material 5 having a cylindrical portion 4 is obtained asshown in FIG. 2(C). A volume of this cylindrical portion 4 is largerthan a volume of the seal ring to be manufactured. Especially, a lengthin the axial direction of this cylindrical portion 4 is longer than alength in the axial direction of the seal ring to be manufactured.

The cylindrical portion 4 of the above second preliminary intermediatematerial 5 is subjected to plastic working in the successive dimensionregulating step and this cylindrical portion 4 is made into a firstintermediate cylindrical material 6 shown in FIG. 2(D). In the abovedimension regulating step, the working is executed as follows.

In a state that an outer circumferential face of the cylindrical portion4 is held by a die (not shown) having a circumferential innercircumferential face having a predetermined inner diameter and also theinner circumferential face of the cylindrical portion 4 is not held, thecylindrical portion 4 is pressed (axially compressed while plasticdeformation) in an axial direction to become a desired dimension, thatis, an axial dimension of the seal ring to be manufactured, between apair of flat faces (e.g., receiving step portion formed on the innercircumferential face of an end portion of the die and a forward end faceof a pushing die inwardly fitted to the die) which are arrangedcoaxially and move axially so as to approach/separate to each other.

Accompanying with thus performed plastic deformation in which axiallycompressed, the outer diameter and axial dimension of the cylindricalportion 4 are regulated to predetermined values. Further, the excessiveportion is swelled radially inward and a first inter mediate cylindricalmaterial is obtained. An inner diameter of the first intermediatecylindrical material 6 is smaller than an inner diameter of the sealring to be manufactured.

In the embodiment shown in FIG. 2, as shown in FIG. 2(E), after formingthe first intermediate cylindrical material 6, the cut-off step isexecuted so as to cut off the first intermediate cylindrical material 6from the metal plate 1. This cut-off step is executed by punchingworking by using a press machine.

The first intermediate cylindrical material 6, which has been cut offfrom the metal plate 1, is successively subjected to ironing working inwhich the inner diameter size is expanded to a proper value (an innerdiameter size of the seal ring to be manufactured). In this ironingstep, while an outer circumferential face of the first intermediatecylindrical material 6 is being restricted so that the outer diameterdoes not expand, an ironing punch having proper outer diameter (whichagrees with the inner diameter of the seal ring to be manufactured) ispushed into from axially one side at radially inner side of the firstintermediate cylindrical material 6. By pushing the ironing punch, theexcessive portion exist on the inner circumferential face portion of thefirst intermediate cylindrical material 6 is collected to axially otherend side (lower side of FIG. 2(F)), and a second intermediatecylindrical material 8 having an inwardly flange-shaped excessive flangeportion 7 formed on the inner circumferential face of the axially otherend portion, as shown in FIG. 2(F), is formed.

This second intermediate cylindrical material 8 is sent to the nextexcessive removing step and the excessive flange portion 7 is removed.In this excessive removing step, when a punch having proper outerdiameter (which agrees with the inner diameter size of the seal ring tobe manufactured) is inserted into the second intermediate cylindricalmaterial 8, the excess flange portion 7 is removed and the seal ring 34shown in FIG. 2(G) is obtained.

Here, this working of the seal ring 34 can be completed at the stageshown in FIG. 2(G). However, when it is difficult to attain the innerdiameter or to attain the property of the inner circumferential face ofthe seal ring 34 at the stage of FIG. 2(G), as shown in FIG. 2(H),re-ironing working may be executed in which the inner circumferentialface of the seal ring 34 is rubbed by an ironing jig.

In any case, the seal ring 34 obtained as described above is sent to astep, which is different from the step of the present invention, inwhich a predetermined working is executed for the seal ring 34.Concerning the seal ring 34 sent to the different step as describedabove, the outer diameter, axial dimension and inner diameter arerespectively regulated at proper values. Therefore, it is unnecessary tocut the axially end portion by lathe turning working. Further, it isunnecessary to execute working such as extruding requiring a strongworking force. Therefore, the manufacturing cost of the seal ring 34 canbe reduced.

According to the working method of the first embodiment described above,the seal ring 34 having the inner diameter, outer diameter and axialdimension which are regulated at proper values, can be industriallymass-produced in low cost. Furthermore, it is possible to manufacturethe seal ring 34 by a working device of which running cost is low. Inthe seal ring 34 obtained, the outer diameter and axial dimension areregulated at proper values in the dimension regulating step and theinner diameter is regulated at a proper value by the ironing step andthe excessive removing step. Accordingly, a highly accurate seal ring 34can be obtained in which the dimensions are regulated at proper valueswithout cutting off the axially end portion by lathe turning.

Working Method of the Second Embodiment

FIGS. 3 to 7 are views showing the working method of the secondembodiment. In the present embodiment, when the steps shown in FIGS.3(A) to 3(G) are executed in order, the metal plate 1 is worked into theseal ring 34. These steps are substantially the same as those of theworking method of the first embodiment. Even in the present embodiment,the re-ironing step shown in FIG. 2(H) can be executed. The presentembodiment is characterized as follows. As the metal plate 1 describedabove, a long metal plate is used which is delivered from an uncoilernot shown and wound up by a recoiler not shown, so that the steps ofFIGS. 3(A) to 3(G) can be successively executed in this order. While thelong metal plate 1 is being synchronized with the progress of workingand intermittently fed at a pitch (interval/pitch=integer) correspondingto the interval between the working devices arranged adjacent to eachother so as to execute each step, the steps shown by FIGS. 3(A) to 3(G)are executed in order.

Therefore, in the present embodiment, in any step shown by FIGS. 3(A) to3(G), without cutting off the long metal plate 1 all over the width, thelong metal plate 1 is successively fed according to the progress of theworking of the seal ring 34. The width size of the metal plate 1 isensured so that both end portions in the width direction of the metalplate 1 can be left being connected with each other even in a state inwhich the second circular hole 10, which is larger than the circularhole 2 shown in FIG. 3(B), is formed on the long metal plate 1 broughtout from the uncoiler in the cut-off step shown in FIG. 3(E) (the widthsize>the diameter of the second circular hole 10). After the firstintermediate cylindrical material 6 (and the second intermediatecylindrical material 8 made in the following steps), which has beenpunched out from the inside of the second circular hole 10 in the abovecut-off step, is subjected to a predetermined working, it is fit intothe inside of the second circular hole 10 again. Then, the firstintermediate cylindrical material 6 is sent to a working device forexecuting the next working in accordance with the feed of the metalplate 1. As described before, the steps shown in FIGS. 3(A) to 3(G) arethe same as the steps shown in FIGS. 2(A) to 2(G) described before.Therefore, the redundant explanations are omitted here and to fit thefirst intermediate cylindrical material 6 into the inside of the secondcircular hole 10 again (re-fitting step) so that the steps shown inFIGS. 3(A) to 3(G) can be successively executed in order will be mainlyexplained below.

The cut-off step and the re-fitting step shown in FIG. 3(E) are executedby the working device shown in FIG. 4. In the working device shown inFIG. 4, while the metal plate 1 is being pressed between an upper faceof the cylindrical die 14 and a lower face of the presser die 12, whichelevates under the condition that a downward elastic force is given, thefirst intermediate cylindrical material 6 is pushed into the die 14 bythe punch 13, so that the first intermediate cylindrical material 6 iscut off from the metal plate 1. On the inner diameter side of the die14, the push-back die 15, which is given an upward elastic force, isprovided, so that the first intermediate cylindrical material 6 can begiven an upward elastic force. However, a push-back die 15 is retreateddownward at the time of lowering the punch 13 when a collision block 16provided in the central portion on the upper face collides with a lowerend face of the punch 13.

The cut-off step and the re-fitting step shown in FIG. 3(E), in whichthe working device shown in FIG. 4 is used, are executed in the order ofFIGS. 5(A) to 5(C). First, as shown in FIG. 5(A), the first intermediatecylindrical material 6, which is still connected to the metal plate 1,is inwardly fitted to an upper end portion of the die 14. Next, togetherwith a ram 17 composing the working machine, the presser die 12 and thepunch 13 are lowered. As shown in FIG. 5(B), while the metal plate 1 isbeing held between a lower face of the presser die 12 and an upper faceof the die 14, the first intermediate cylindrical material 6 is pushedinto the die 14 by the punch 13.

As a result, the first intermediate cylindrical material 6 is cut offfrom the metal plate 1 and at the same time the second circular hole 10is formed on the metal plate 1. When the presser die 12 and the punch 13are raised together with the ram 17 after the first intermediatecylindrical material 6 has been cut off from the metal plate 1, as shownin FIG. 5(C), the push-back die 15 r which has been lowered being pushedby the punch 13, is raised. As a result, the first intermediatecylindrical material 6 is pushed into the second circular hole 10 bythis push-back die 15 and held inside the second circular hole 10. Whenthe metal plate 1 is moved at this time, the first intermediatecylindrical material 6 is sent to the next ironing step and there-fitting step shown in FIG. 3(F).

The ironing step and the re-fitting step shown in FIG. 3(F) are executedby the working device shown in FIG. 6. In the working device shown inFIG. 6, the metal plate 1 is pressed between an upper face of thereceiving die 18, which is given an upward elastic force, and a lowerface of a elevating cylindrical ironing die 20. By the ring punch 19,the first intermediate cylindrical material 6 is pushed into the ironingdie 20. The ring punch 19 is arranged on the inner diameter side of thereceiving die 18 being capable of elevating independently from thereceiving die 18 and given an upward elastic force. Onto the innerdiameter side of the ring punch 19, an ironing punch 21, which irons aninner circumferential face of the first intermediate cylindricalmaterial 6 so that the first intermediate cylindrical material 6 can beformed into the second intermediate cylindrical material 8, is fixed.The ring punch 19 is arranged so that it can be elevated in theperiphery of this ironing punch 21. An amount of the maximum lift isrestricted by an engagement of the inner circumferential face of thering punch 19 with the outer circumferential face of the ironing punch21. Specifically, as shown in FIGS. 6 and 7(A), the amount of themaximum lift is set so that an upper end edge of the ring punch 19 canbe located at a position a little lower than an upper face of thereceiving die 18 under the condition that the receiving die 18 iselevated at the highest position. On the inner diameter side of the die20, a push-back die 22, which is given a downward elastic force, isarranged.

The ironing step and the push-back step shown in FIG. 3(F), in which theworking device shown in FIG. 6 described above is used, are executed inthe order of FIGS. 7(A) to 7(C). First, as shown in FIG. 7(A), the firstintermediate cylindrical material 6, which is held inside the secondcircular hole 10, is inwardly fitted to an upper end portion of theabove receiving die 18 and its end face is made to collide with an upperend edge of the ring punch 19. Next, as shown in FIG. 7(B), a ram 24composing the above working machine, the ironing die 20 and thepush-back die 22 are lowered, the metal plate 1 is pushed downward by alower face of this ironing die 20, and the first intermediatecylindrical material 6 is pulled out upward from the second circularhole 10 and then sent to the inner diameter side of the ironing die 20by the ring punch 19. Onto the inner diameter side of the firstintermediate cylindrical material 6 which has been sent onto the innerdiameter side of the ironing die 20, the ironing punch 21 is pushed whenthe ironing die 20 is further lowered together with the ram 23.

As a result, an inner diameter of the first intermediate cylindricalmaterial 6 is regulated at a predetermined size and the excess portionis collected to an upper end portion on the inner circumferential face.The first intermediate cylindrical material 6 is formed into the secondintermediate cylindrical material 8, at the upper end portion on theinner circumferential face of which the excessive flange portion 7 shownin FIG. 3(F) is formed.

After the second intermediate cylindrical material 8 has been formed asdescribed above, the ironing die 20 is raised together with the ram 23.Then, the metal plate 1, which has been lowered being pushed by thisironing die 20, is raised together with the receiving die 18 and at thesame time the push-back die 22 is lowered with respect to the ironingdie 20. At this timer this push-back die 22 pushes downward theexcessive flange portion 7 shown in FIG. 3(F) which has been just formedon the inner circumferential face of the upper end portion of the secondintermediate cylindrical material 8. Therefore, the second intermediatecylindrical material 8 is pushed into the second circular hole 10 andheld inside the second circular hole 10.

When the metal plate 1 is moved, the second intermediate cylindricalmaterial 8 is sent to the next excessive removing step and the push-backstep shown in FIG. 3(G). Here, when the re-ironing step shown in FIG.2(H) is executed after completing the excessive removing step shown inFIG. 3(G), the seal ring 34 obtained in this excessive removing step ispushed back into the second circular hole 10 on the metal plate 1 in thepush-back step. On the other hand, in the case where the seal ring 34obtained in the excessive removing step is sent to a step in which apredetermined working is executed for this seal ring 34 differently fromthe present invention, the push-back step described above can beomitted, that is, the seal ring 34, which has been separated from themetal plate in FIG. 3(G), can be taken out as it is.

In the present embodiment configured as described above, in addition tothe action and effect obtained in the first embodiment, it is possibleto industrially mass-produce needle bearings by a continuous workingdevice of which running cost is inexpensive. In the present embodiment,the metal plate 1 is a long metal plate 1 delivered from an uncoiler andwound round a recoiler. The first and the second cylindricalintermediate material 6, 8, which have been cut off from the metal plate1 in the cut-off step, are pushed again inside the second circular hole10 on the metal plate 1. Therefore, the intermediate materials 6, 8 canbe sent to the next working step together with the metal plate 1. Thatis, as compared with the transfer working, it is possible to reduce theequipment investment. Further, it is possible to execute a successivelyfeeding working, the working efficiency of which is high, that is, theworking cycle time of which is short. Therefore, the working cost of theseal ring 34 can be more reduced.

Working Method of the Third Embodiment

FIG. 8 is a view showing a working method of the third embodiment. Inthis embodiment, in the ironing step and the push-back step shown inFIG. 8(F), a direction, in which the second cylindrical intermediatematerial 8 is pulled out from the second circular hole 10 on the metalplate 1 and fitted into the second circular hole 10 again, is upsidedown with respect to the metal plate 1 when it is compared with theworking method of the second embodiment. When the direction is reversedas described above, of course, the constitution of the working deviceshown in FIGS. 6 and 7 is made different. The constitution of the otherportions is the same as that of the working method of the secondembodiment described before. Therefore, the redundant explanations areomitted here.

Working Method of the Fourth Embodiment

FIG. 9 is a view showing a working method of the fourth embodiment. Inthis embodiment, after the burring step shown in FIG. 9(C), the cut-offstep and the push-back step shown in FIG. 9(D) are set. The constitutionof the other portions is the same as that of the working method of thesecond embodiment described before. Therefore, the redundantexplanations are omitted here. In short, when executing the presentinvention, as long as the cut-off step is executed after the burringstep, the cut-off step can be set at an arbitrary timing whenconsideration is given to the easiness of the working and the ensuringthe accuracy of working.

In the drawn cup needle roller bearing 30 having a seal ring of thepresent embodiment, when the seal ring 34 is formed by press working, itis possible to ensure high dimensional accuracy of the seal ring 34.Therefore, it is possible to prevent abrasion of the seal ring causedwhen it comes into contact with an opponent member. Since the needlebearing includes the seal ring 34, it is possible to control a quantityof lubricant passing through the needle bearing. Since the seal ring 34is a floating seal, torque required for the bearing can be reduced ascompared with a bearing in which a contact type seal is used. In thisconnection, it is preferable that the seal ring 34 is 1.0 to 2.5 mm inthe height of the cross section of the bearing because the thickness ofthe bearing can be reduced.

Especially, the heat treatment is not executed for the seal ring 34after the seal ring 34 has been formed by press working. Therefore, themanufacturing cost can be reduced.

Working Method of the Fifth Embodiment

In the working method of the seal ring of the present embodiment, whenthe long metal plate drawn out from the uncoiler is punched into acircular shape by a press working, the metal plate 1 shown in FIG. 10(A)is formed.

Next, as the first step, when a central portion of the metal plate 1 ispunched by means of punching working executed by a press, an annularfirst preliminary intermediate material 3 shown in an upper stage ofFIG. 10(B) is formed. A disk-shaped scrap 51 shown in a lower stage ofFIG. 10(B), which is generated as a result of punching, is discarded orutilized as material for making a smaller seal ring.

In the second step, the first preliminary intermediate material 3 issubjected to burring working in which a portion close to the innerdiameter of the first preliminary intermediate material 3 is bent in theaxial direction at a right angle. As well known in the field of metalworking, this burring is executed in such a manner that a punching dieis pushed into a portion close to the inner diameter of the firstpreliminary intermediate material 3 while holding a portion close to theouter diameter of the first preliminary intermediate material 3 fromboth sides by a pair of presser dies. When the burring described aboveis executed, obtained is a second preliminary intermediate material, ofwhich cross section is an L-shape, of which entire shape is annular,which has the cylindrical portion and an outward flange portion 9 whichis bent radially outward from one axially end portion of the cylindricalportion 4 as shown in FIG. 10(C).

According to the working method of the seal ring of the presentinvention, a highly accurate thin ring is formed out of the cylindricalportion 4 of the second preliminary intermediate member 5. On the otherhand, a portion of the above outward flange portion 9 existing outsidein the radial direction with respect to the outer circumferential faceof this cylindrical portion 4 is discarded as an annular scrap 52 (referto a lower stage of FIG. 10(D)) in the third step described later.

Next, in the successive third step, the second preliminary intermediatematerial 5 is subjected to punching working by a press working so as toremove the outward flange portion 9 and the first intermediatecylindrical material 6, which is shown in an upper stage of FIG. 10(D),is obtained. An outer diameter of the first intermediate cylindricalmaterial 6 coincides with the outer diameter of the seal ring 34 to bemanufactured.

In the successive fourth step, the first intermediate cylindricalmaterial 6 obtained as described above is subjected to cold rollingworking. By the plastic working executed by this cold rolling working,the inner and outer diameters and the cross section shape of the firstintermediate cylindrical material 6 are regulated and the firstintermediate cylindrical material 6 is made into the seal ring 34 shownin FIG. 10(E), the shape accuracy and the dimensional accuracy are setso as to satisfy their requirements. Cold rolling working for workingthe first intermediate cylindrical material G into the seal ring 34 willbe explained in more detail referring to FIGS. 11 to 13.

The first intermediate cylindrical material 6 is supported by an annulardie 40 being inwardly fitted to the die 40. This die 40 has inner andouter circumferential faces which are cylindrical faces concentricallyformed to each other. This die 40 is rotatably supported by a pluralityof supporting rollers not shown (in a state of preventing displacementin radial direction). The respective outer circumferential faces of thesupporting rollers come into rolling contact with the outercircumferential face of the die 40. The die 40 has an inner diameteragreeing with the outer diameter of the seal ring 34 (and the firstintermediate cylindrical material 6) to be manufactured. In the fourthstep described above, this first intermediate cylindrical material 6 isheld on the inner circumferential face of the die 40. Under thiscondition, the first intermediate cylindrical material 6 is pressed by apushing roller 41 to the inner circumferential face of the die 40 in thedirection of the arrow shown in FIG. 11.

In a portion on an outer circumferential face of the intermediateportion of the pushing roller 41 corresponding to the first intermediatecylindrical material 6, a recessed groove 42 is formed all over thecircumference. A cross-sectional shape of this recessed groove 42 isrectangle and the width size in the axial direction coincides with awidth size of the seal ring 34 to be manufactured. The depth of therecessed groove 42 in the radial direction of the pushing roller 41 isnot more than the thickness size of the seal ring 34 to be manufactured.When the first intermediate cylindrical material 6 is worked into theseal ring 34, the above pushing roller 41 is pressed onto an innercircumferential face of the die 40 while rotating. A portion in thecircumferential direction of the first intermediate cylindrical material6 is strongly pressed between the inner circumferential face of the die40 and an inner face of the recess groove 42.

When the pushing roller 41 presses the portion in the circumferentialdirection of the first intermediate cylindrical material 6 as describedabove, while the die 40 is rotating in the same direction of the rollingdirection of the pushing roller 41, the die 40 receives a pushing forcegiven by the pushing roller 41. The first intermediate cylindricalmaterial 6 is also rotated together with the die 40. Accordingly, theportion of the first intermediate cylindrical material 6, which isstrongly pressed between the inner circumferential face of the die 40and the inner face of the recessed groove 42, is continuously changed inthe circumferential direction. As a result, a cross-section of the firstintermediate cylindrical material 6 is changed all over thecircumference as shown in FIGS. 13(A) to 13(B). That is, thecross-sectional shape of the first intermediate cylindrical material 6is plastically deformed so as to agree with the inner circumferentialface of the die 40 and the inner face of the recessed groove 42. In thisway, the seal ring 34 is formed. That is, at the time of the abovedescribed fourth step in which the die 40 and the pushing roller 41 areused, without changing the outer diameter and the outer circumferentialface of the first intermediate cylindrical material 6, the innerdiameter and the shape of the inner circumferential face are changed sothat the material is worked into the sealing 34.

The working method of a seal ring of the present embodiment, includesthe following first to fourth steps.

First Step: When the metal plate is punched out, the annular firstpreliminary intermediate material 3 is obtained.

Second Step: When burring working is executed in which a portion closeto the inner diameter of the first preliminary intermediate material 3is bent in the axial direction at a right angle, the second preliminaryintermediate material 5, the cross-sectional shape of which is anL-shape and the entire shape of which is formed into an annular shape,is obtained which includes the cylindrical portion 4 and the outwardflange portion 9 bent outside in the radial direction from one axiallyend portion of this cylindrical portion 4.

Third Step: The outward flange portion 9 of the second preliminaryintermediate material 5 is removed and the first intermediatecylindrical material 6 is formed.

Fourth Step: The inner and outer diameters and the cross-sectional shapeof the first intermediate cylindrical material 6 are regulated by coldrolling working, so that the seal ring 34 has the required shapeaccuracy and dimensional accuracy. In this connection, this shapeaccuracy includes the accuracy of the sectional-shape and also theaccuracy related to the entire shape such as the circularity.

Due to the foregoing, the seal ring 34, which is a highly accurate thinring in which the dimensions of the inner and outer diameters and theaccuracy of the cross-sectional shape must be sufficiently ensured, canbe manufactured at a low manufacturing cost. That is, in the presentembodiment, when the thickness of a metal plate, which becomes the metalplate 1, is selected corresponding to the radial thickness of the sealring 34 to be manufactured, even the thin seal ring 34 can bemanufactured while the necessary accuracy with respect to the thicknessis being ensured. In other words, while the accuracy of the inner andouter diameters is being maintained sufficiently high, it is possible tomanufacture a highly accurate thin ring having high shape accuracy.Especially, the cold rolling working for working the first intermediatecylindrical material 6 into the seal ring 34 is executed by utilizingthe die 40 and the pushing roller 41 as described above. Therefore, theseal ring 34 having high shape accuracy and dimensional accuracy can behighly efficiently manufactured.

At the time of executing the fourth step, the first intermediatecylindrical material 6 is held on the inner circumferential face of theannular die 40. Under this condition, the inner circumferential face ofthe first intermediate cylindrical material 6 is pressed onto the innercircumferential face of the die 40 by the pushing roller 41. It ispreferable that the first intermediate cylindrical material 6, of whichouter diameter agrees with the outer diameter of the completed seal ring34, is formed in the third step. After that, in the fourth step, theinner diameter and the shape of the inner circumferential face arechanged without changing the outer diameter of the first intermediatecylindrical material 6. Due to the foregoing, the seal ring 34 havinghigh shape accuracy and dimensional accuracy, can be efficientlymanufactured.

Working Method of the Sixth Embodiment

FIGS. 14 to 16 are views showing a working method of the sixthembodiment. In the fifth embodiment described before, four cornerportions (both axial end edges of the inner and outer circumferentialfaces) of the cross-sectional shape of the seal ring 34 obtained arepointed (that is, a radius of curvature of the cross-sectional shape ofthe portion concerned is very small). On the other hand, in the presentembodiment, it is intended that four corner portions of thecross-sectional shape are formed into protruding arc faces (that is, thecorners are formed into R-shaped portions). Concerning the R-shapedcorner portions at both axial end-edges of the inner circumferentialedge, even in the working method of the fifth embodiment describedbefore, when the R-shaped corner portions are provided in the bottomcorner portions in the recess groove 42 formed on the outercircumferential face of the pushing roller 41 (that is, when thecross-sectional shape of the bottom face corner portions are formed intorecessed arc faces), the four corner portions of the cross-sectionalshape can be formed into the protruding arc faces. On the other hand,when the R-shaped corner portions of both axial end edges of the outercircumferential face are formed only out of the shape of the innercircumferential face of the die, it becomes impossible to take out acompleted seal ring from the inner circumferential face of the dieconcerned.

In view of the above circumstances, the working method of the presentembodiment has been accomplished. It is intended to realize a workingmethod of taking out the seal ring 34, in which the corner R portionsare formed not only at both axial end edges of the inner circumferentialface but also at both axial end edges of the outer circumferential face,from the die 40 a. In this connection, FIGS. 14(A) to 14(C) showing themanufacturing method of the present embodiment are the same as FIG.10(A) to 10(C) showing the manufacturing method of the fifth embodiment.FIG. 14(E) is the same as FIG. 10(D) described before except for thatthe corner-R portion 11 described later is formed at a portion. Thepresent embodiment is characterized in that the preliminary working stepshown in FIG. 14(D) is provided in the present embodiment and a shape ofthe inner circumferential face of the die 40 a used for cold rollingworking executed in FIG. 14(F) is devised. Illustrations andexplanations overlapping those of the working method of the fifthembodiment are omitted or simplified here and only different points fromthe working method of the fifth embodiment will be mainly explained asfollows.

In the manufacturing method of the sixth embodiment which is consideredaccording to the above intention, the corner R portion 11 shown in FIG.15 is formed in one end edge portion of the outer circumferential faceof the first intermediate cylindrical material 6 shown in the upperstage of FIG. 14(E). The step of forming the corner R portion 11 may beexecuted before the first intermediate cylindrical material 6 a is seton the inner circumferential face of the die 40 a shown in FIG. 16 (thatis, before the first intermediate cylindrical material 6 a is inwardlyfitted to the annular die 40 a). That is, the step of forming the cornerR portion 11 may be executed in any of between FIGS. 14(B) and 14(C)between FIGS. 14(C) and 4(E) and between FIGS. 14(E) and 14(F). In thepresent embodiment, before the second preliminary intermediate material5 shown in FIG. 14(C) is worked to be the first intermediate cylindricalmaterial 6 shown in FIG. 14(E), the corner R portion 11 shown in FIG. 15is formed at a forward end edge portion of the outer circumferentialface of the cylindrical portion 4 at the step shown in FIG. 14(D). Thecorner R portion 11 is formed as follows. Under the condition that thecylindrical portion 4 is outwardly fitted to a cylindrical core, anannular press die, on the forward end face of the entire circumferenceof which a pressing face of a recess arc face is formed, is pressedagainst the forward end edge portion of the outer circumferential faceof the cylindrical portion 4, and the forward end edge portion of theouter circumferential face can be plastically deformed.

The third preliminary intermediate material 5A shown in FIG. 14(D), inwhich the corner R portion 11 is formed in the forward end edge portionof the outer circumferential face of the cylindrical portion 4 in thepreliminary working step, is subjected to punching working by a pressworking in the same manner as in the fifth embodiment. Then, the outwardflange 9 is removed and the first intermediate cylindrical material 6shown in the upper stage portion of FIG. 14(E) is obtained. The corner Rportion described above is provided at one axial end edge of the outercircumferential face in both axial end edges of the inner and outercircumferential faces of the first intermediate cylindrical material 6.On the other hand, the other axial end edge of the outer circumferentialface and both axial end edges of the inner circumferential face are leftbeing pointed. Therefore, in the fourth step shown in FIGS. 14(E) to14(F), when the inner and outer diameters and the cross-sectional shapeof the first intermediate cylindrical material 6 are regulated, thecorner R portions are formed at the other axial end edge of the outercircumferential face and both axial end edges of the innercircumferential face. In this way, obtained is the seal ring 34 in whichthe corner R portions are formed in all four corner portions and has thehigh cross-sectional shape accuracy and high dimensional accuracy.

In order to obtain the above seal ring 34, an inner circumferential faceof the annular die 40 a used for the fourth step is formed into astepped cylindrical face on which the large diameter portion 43 and thesmall diameter portion 44, which are cylindrical faces concentric toeach other, are continued by the step portion 45 as shown in FIG. 16.This step portion 45 is a recessed arc face, the cross section of whichis one fourth arc shape. Concerning both axial end corner portions ofthe bottom portion of the recessed groove 42 a formed on the outercircumferential face of the pressing roller 41 a, the cross-sectionalshape is formed into a recessed arc face of one fourth arc. Theconstitution of the other portions of the cold rolling working device isthe same as that of the working method of the fifth embodiment describedbefore.

In the present embodiment, the first intermediate cylindrical material 6is inwardly fitted to the die 40 a described above while the other axialend edge (the sharp edge) of the outer circumferential face of the firstintermediate cylindrical materiel 6 is being opposed to the step portion45 which is the recessed arc face provided on the inner circumferentialface of the die 40 a. In the same manner as that of the fifthembodiment, the first intermediate cylindrical material 6 is pressedagainst the inner circumferential face of the die 40 a by the pressingroller 41 a described before. As a result of this pressing working, thecross-sectional shape of the first intermediate cylindrical material 6is changed from FIG. 16(A) to FIG. 16(B) all over the circumference.That is, the cross-sectional shape of this first intermediatecylindrical material 6 is plastically deformed so as to agree with theinner circumferential face of the die 40 a and the inner face of therecessed groove 42. In this way, the seal ring 34 is formed. At thistime, a shape of the recessed arc face composing both axial end cornerportions of the bottom portion of the recessed groove 42 is transferredonto both end edge portions of the first intermediate cylindricalmaterial 6 and a shape of the step portion 45 is transferred onto theother axial end edge portion on the outer circumferential face of thefirst intermediate cylindrical material 6. The corner R portion 11 isoriginally formed in one axial end edge portion of the outercircumferential face of the first intermediate cylindrical material 6.Therefore, in both axial end edge portions of the inner and outercircumferential faces of the seal ring 34 obtained as a result of thefourth step, the corner R portions having a cross-sectional shape of onefourth arc are respectively formed.

According to the working method of the seal ring of the presentembodiment, the seal ring 34 of high quality, in which the corner Rportions (the protruding arc shape portions), the cross-sectional shapeof which is one fourth arc shape, are respectively formed in both axialend edge portions of the inner and outer circumferential faces, can beefficiently manufactured by an industrial method.

That is, when the corner R portions are simply formed in both axial endedge portions on the inner and outer circumferential faces, it ispossible to form the corner R portions in such a manner that the sealring 34 made by the working method of the fifth embodiment is subjectedto machining such as lathe turning or grinding working. However,according to the method in which the corner R portions are formed bymachining as described above, the manufacturing cost is raised and thecost of the seal ring is raised. Accordingly, it is not avoidable fromincreasing of the manufacturing cost of a machine such as a transmissionfor an automobile.

On the other hand, according to the working method of the presentembodiment, after the first step and before the fourth step, that is, inany of between the first step and the second step, between the secondstep and the third step and between the third step and the fourth step,the preliminary forming, by which the cross-sectional shape of at leastone end edge in both end edges of the outer circumferential face isformed into a protruding arc shape of one fourth arc shape, is conductedon the intermediate material (one of the first preliminary intermediatematerial 3 to the first intermediate cylindrical material 6).Accordingly, it is possible to efficiently manufacture a seal ring 34 ofhigh quality, the end edges of which are not sharp.

Manufacturing Method of the Seventh Embodiment

Next, explanations will be made into a working method of the seventhembodiment in which a seal ring is subjected to the abrasion resistancetreatment. The seal ring 34 worked by any of the working methods of thefirst to the sixth embodiment is not subjected to heat treatment aftercompleting the press working in order to prevent the seal ring 34 frombeing deformed by heat treatment such as quenching and tempering.Therefore, work hardening, which is caused when a metal plate is worked,is anticipated. In the working methods of the first to the fourthembodiment, work hardening is caused by press working. In the workingmethods of the fifth and the sixth embodiment, in addition to workhardening caused by press working, work hardening is caused by coldrolling working. Even when work hardening is caused, since the seal ring34 composes a floating seal, no problems are caused when the seal ring34 is usually used. However, in the case where the drawn cup needleroller bearing 30 is used under a severe condition, it is desirable thatthe seal ring 34 is subjected to the abrasion resistance treatment.

Concerning the treatment for improving abrasion resistance, in order toensure the shape accuracy and the dimensional accuracy required for thethin seal ring 34, it is desirable to use a method in which nodeformation is caused by the treatment for improving abrasionresistance. Specifically, it is considered to use the method ofnitriding. Examples of nitriding are: gas nitriding, salt bath nitridingand ion nitriding. It is desirable to use Nv Nitriding Process (BrandName of Air Water Co.) in which the treatment can be executed at arelatively low temperature.

Nv nitriding process is executed as follows. For the seal ring 34 formedinto a cylindrical shape by the working method of any of the first tothe sixth embodiment, fluoridizing process is executed by using, forexample, fluorine gas such as NF3. After that, gas nitriding is executedso as to form a nitriding layer on a surface of the seal ring 34. By thefluoridizing process, Cr oxide, which obstructs nitriding, is removedfrom a surface of the work to be treated and a fluoridized layer, whichactivates the surface of the work to be treated, is formed. Due to theforegoing, even when nitriding is executed at a low temperature of about400° C., a relatively uniform nitriding layer is formed. As describedabove, both fluoridizing and nitriding processes are executed at a lowtemperature. Therefore, the seal ring 34 is not deformed. Accordingly,the high dimensional accuracy and the high shape accuracy of the sealring 34 worked by the working methods of the first to the sixthembodiment can be maintained and it is possible to manufacture thehighly accurate seal ring 34. When the seal ring 34 is subjected to Nvnitriding process as described above, it is possible to form a nitridinglayer having the surface hardness of Hv400 or more and the thickness of5 to 20 μm. Accordingly, while the deformation of the seal ring 34caused in the treatment for improving abrasion resistance is beingprevented, the abrasion resistance property can be enhanced.

In this connection, it should be noted that the present invention is notlimited to the above specific embodiments. Variations and improvementscan be appropriately made.

In the present embodiment, the outer ring shell 31 is used whichincludes a raceway surface 31 a formed on the inner circumferential faceand also includes inward flange portions 31 b, 31 c formed in both endportions. However, it is possible to use an inner ring shell whichincludes a raceway surface formed on the outer circumferential face andalso includes outward flange portions formed in both end portions. Inthis case, the seal ring is provided outside the shell between the endface of the cage and the outward flange portion.

EXAMPLES

Next, a comparison test was made with respect to the dynamic torque andthe quantity of lubricant passing through a needle bearing by using adrawn cup needle roller bearing having a seal ring of the presentinvention and by using a conventional plain bearing (a bush). In thecomparison test of the dynamic torque, the height of the cross sectionof the bearing was 1.5 mm with respect to both bearings and the testload was 500N.

In the comparison test of the quantity of lubricant passing through thebearing, the drawn cup needle roller bearing in which a height of thecross section thereof was 1.5 mm and a gap between the seal ring and ashaft was 0.06 mm as the upper limit, was used. Further, the bush, inwhich the height of the cross section was 1.5 mm and the gap of whichwas 0.08 mm as the upper limit, was used. The rotating speed of theshaft was 0 to 3000 rpm. Lubricant was JWS3309 (manufactured by ExxonMobil Co.). The oil pressure was 30 kPa. The oil temperature wasapproximately 80° C. FIG. 17 shows a result of the measurement of thedynamic torque and FIG. 18 shows a result of the measurement of thequantity of lubricant passing through the bearing.

As shown in FIG. 17, in the comparison test of the dynamic torque, itcan be understood that the dynamic torque can be reduced by using thedrawn cup needle roller bearing. Especially, it can be confirmed thatthe effect of reducing the dynamic torque is high in the low speedregion where the fuel consumption efficiency is low.

As shown in FIG. 18, in the comparison test of the quantity of lubricantpassing through the bearing, only the quantity of lubricant passingthrough a bearing of the drawn cup needle roller bearing, the gap ofwhich is 0.06 mm, is larger than the quantity of lubricant passingthrough the bearing of the bush, the gap of which is 0.08 mm, by 4 mL atthe maximum. Therefore, the quantity of lubricant passing through thebearing can be regulated at the same value as that of the bush.

Next, a material was used in which glass fiber was mixed by 25% withpolyamide 46, which is capable of being used at a high temperature andalso capable of being easily manufactured. While the forming conditionwas being changed, cages made of resin of which inner diameter was 45mm, were formed by means of injection molding. The circularity of theouter diameter was compared with respect to the forming conditions andwith respect to whether or not the treatment of annealing was executed.FIG. 19 shows the result of the test.

Here, the test was made in such a manner that four types of cages madeof resin were formed in different conditions and one type of the formedcage was subjected to annealing. In the treatment of annealing, anannealing shaft of 45.22 mm was inserted into the inner diameter of thecage made of resin and held for three hours at 170° C. The circularitywas measured by using a tool microscope in such a manner that the outerdiameter on the gate side and the outer diameter on the ejector sidewere respectively measured at eight points and the average values werefound. In this case, concerning the cages made of resin, the number ofthe cages not subjected to annealing was ten and the number of the cagessubjected to annealing was twenty.

As shown in FIG. 19, the cages made of resin not subjected to thetreatment of annealing were out of the tolerance (±0.1 mm) although thedeviation was slightly different from each other according to theforming condition. On the other hand, all the cages made of resinsubjected to the treatment of annealing were in the tolerance.Therefore, it can be understood that the treatment of annealing iseffective for enhancing the circularity.

Next, tests of the warp deformation were made in three cases of thetreatment for improving abrasion resistance including Tufftride (saltbath nitriding), NV nitriding and NV nitriding (no oxide film). FIG. 20shows amounts of the warp deformation in the above treatment. As aresult, the following was found. In any case of the treatment of NVnitriding, NV nitriding (no oxide film) and Alcoa VG7, amounts of thewarp deformation of all products were in the range stipulated in thestandard, that is, the results were preferable.

The present application of patent is based on the Japanese PatentApplication (Patent Application No. 2006-159699) filed on Jun. 8, 2006and also based on the Japanese Patent Application (Patent ApplicationNo. 2007-010153) filed on Jan. 19, 2007 and the contents are taken inhere as reference.

1. A method of manufacturing a drawn cup needle roller bearing having aseal ring, the drawn cup needle roller bearing comprising: a shellhaving a raceway surface on a circumferential face and also havingflange portions in both end portions; a cage having a plurality ofpockets in a circumferential direction; a plurality of needles retainedin the pockets so that the needles freely rotate along the racewaysurface; and a cylindrical seal ring arranged between an end face of thecage and the flange portion of the shell, wherein the seal ring composesa floating seal and a height of a cross section of the needle rollerbearing is 1.0 to 3.5 mm, the method comprising: forming the seal ringby a press working, the press working comprising: piercing a metal plateto form a first preliminary intermediate material having a firstcircular hole; bending the periphery of the first circular hole so as tobe right angle with respect to the metal plate all over thecircumference to form a second preliminary intermediate material havinga cylindrical portion; pressing the cylindrical portion in an axialdirection, in a state that an outer circumferential face of thecylindrical portion is held by a die and an inner circumferential faceof the cylindrical portion is not held, to regulate an outer diameterand an axial dimension of the cylindrical portion to predeterminedvalues and to cause the excessive portion to be swelled radially inward,thereby obtaining a first intermediate cylindrical material; pushing anironing punch having an outer diameter, which agrees with an innerdiameter of the seal ring to be manufactured, into a radially inner sideof the first intermediate cylindrical material from one axial end of thefirst intermediate cylindrical material, while restricting the outercircumferential face of the first intermediate cylindrical material sothat the outer diameter of the first intermediate cylindrical materialdoes not expand, to collect the excessive portion existing on the innercircumferential face portion of the first intermediate cylindricalmaterial to the other axial end of the first intermediate cylindricalmaterial, thereby forming a second intermediate cylindrical materialhaving an inwardly flange-shaped excessive flange portion formed on theinner circumferential face of the portion on the other axial end,inserting a punch having an outer diameter, which agrees with the innerdiameter of the seal ring to be manufactured, into the secondintermediate cylindrical material to remove the excess flange portion,thereby obtaining the seal ring; and after the bending, cutting off thecylindrical portion, the first intermediate cylindrical material, thesecond intermediate cylindrical material or the seal ring from the metalplate.
 2. The method according to claim 1, wherein after completing thepress working on the seal ring, the seal ring is subjected to atreatment for improving abrasion resistance.
 3. The method according toclaim 1, wherein the cage is made of resin.
 4. The method according toclaim 1, wherein the metal plate is a long metal plate which isdelivered from an uncoiler and wound up by a recoiler, and the metalplate is successively fed according to the progress of the working ofthe seal ring without being cut along its width, wherein the cutting offcomprises forming a second circular hole, which is larger than the firstcircular hole in the metal plate, and punching out the cylindricalportion, the first intermediate cylindrical material or the secondintermediate cylindrical material from the inside of the second circularhole, and after the metal plate, and punching out the cylindricalportion, the first intermediate cylindrical material or the secondintermediate cylindrical material from the inside of the second circularhole is subjected to a predetermined working, it is fitted into theinside of the second circular hole again and is sent to a working devicefor executing the next working in accordance with the feed of the metalplate.